rmis view/print document cover sheet · 2020-01-16 · collects and discharges into tk 10-1 any...

"" RMIS View/Print Document Cover Sheet""

This document was retrieved from the Documentation and Records Manaqement (DRM) ISEARCH System. It is intended for Information only and may not be the most recent or updated version. Contact a Document Sewice Center (see Hanford Info for locations) if you need add it i o n al retrieval i n fo r m at i o n .

Accession #: Dl95067334

Document #: SD-WM-ER-456

TitlelDesc: B PLANT LLW SYSTEM INTEGRITY ASSESSMENT REPORT

Pages: 41

2. TO: ( R e c e i v i n g ~ ~ a n i ~ a t i o n )

B P1 ant/WESF Regulatory Compl i ance

16600/Transition/221B 5 . Proj.lProg.lDept.lDiv.:

15. DATA TRANSMITTED

3. From: (Originating Organization)

M i t iga t ion Systems In teqra t i on

E . J . Walter 6. cog. Engr.:

IEl r u e or Dasdptlon of Data Tranamittsd

IC1 ID1 Shoat IBI DooumantIDrawing No. I No. I r: 1

I

WHC-SD-WM-ER-456 0 B P lant Low Level Waste I n t e g r i t y Assessment Report

I I I I I I

Page 1 of

I.EDT 6 0 4 1 5 2 4. Related EDT No.:

7. Purchase Order No.:

N/A

N/A

221B/B-P1 ant

N/A

N/A

12/13/95

9. Equip./Component No.:

10. Systen/Bldg.lFacility:

12. Major Assn. Dug. No.:

13. Pernit/Pernit Application No.:

14. Required Response Date:

( F ) ( G ) ( H ) ( 1 )

Desig- for nator or Appmvai Reason Origi- ReceiV-

nator Trans- Dispo- Diepa- m i n d aitian sition

EeS 1 I I ECO

3333

[I Approved [I Approved ulcDnnents (1 Disapproved ulcunnents

Originator for Receiving Organization

ED-7400-1n-2 (04/94) GEF097

807400.1 72-1 l07/91)

WHC-SD-WM-ER-456. Rev. 0

B PLANT LOW LEVEL WASTE SYSTEM INTEGRITY ASSESSMENT REPORT

E. J . Walter Westi nghouse Hanford Company, R i c h l and, WA 99352 U. S . Department o f Energy C o n t r a c t DE-AC06-87RL10930

EDT/ECN: EDT-604152 0 r g Code: 74750 8&R Code: EW3135090

UC: 512 Charge Code: KB53D T o t a l Pages: 38

Key Words: I n t e g r i t y Assessment Repor t , I A R . Assessment, WAC, 8 P l a n t

A b s t r a c t : T h i s document p rov ides t h e repor- t o f t h e i n t e g r i t y assessment a c t i v i t i e s f o r t h e B P l a n t low l e v e l waste system. The assessment a c t i v i t i e s were i n response t o requirement:; o f t h e Washington S t a t e Dangerous Waste Regu la t i ons , Washington A d m i n i s t r a t i v e Code (WAC), 173- 303-640. T h i s i n t e g r i t y assessment r e p o r t suppor t s compl l a n c e w i t h Hanford Federal Faci 1 i t y Agreement and Conijent Order i n t e r i m m i l e s t o n e t a r g e t a c t i on M-32-07 -T03.

TRADEMARK DISCLAIMER. Reference herein t o any s p i f i c c m r c i a l product, process, or service by trade name, tradernark, manufacturer, or otheruise, does not necessarily const i tu te or i n p l y i t s endorsement, r e c m n d a t i o n , or favoring by the United States Governnent or any agency thereof or i t s contractors o r subcontractors.

Printed i n the United States of America. TO obta in copies of t h i s docunent, contact: UHC/BCS D o c m t Control Services, P.O. Box 1970, Mai ls top H6-08, Rich1 Fax (509) 376-4989.

pd 12 - 1.5. 95 Reyase Aipproval # Date

Approved for Public Release

A-6400-073 (10195) GEF321

WHC-SD-WM-ER-456 Rev. 0

CONTENTS

1.0 INTRODUCTION . . 2.0 OBJECTIVE .

- PAGE

1

1

3.0 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 .0 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.1 DESCRIPTION AND FUNCTION OF THE LOW LEVEL WASTE SYSTEM . . . . 5 4.2 DESIGN STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . 6

4.2.1 Waste Tank Design Standards . . . . . . . . . . . . . 6 4.2.2 Waste Tank A n c i l l a r y Equipment Design Standards . . . 8

4.2.2.1 Waste P i p i n g . . . . . . . . . . . . . . . . . a 4.2.2.2 Other Equipment . . . . . . . . . . . . . . . 9

4.2.3 Secondary Containment . . . . . . . . . . . . . . . . . 9 4.3 DANGEROUS WASTE CHARACTERISTICS . . . . . . . . . . . . . . . 11 4.4 EXISTING CORROSION PROTECTION MEASURES . . . . . . . . . . . . 12 4.5 AGE OF THE WASTE TANK SYSTEM . . . . . . . . . . . . . . . . . 12 4.6 INTEGRITY EXAMINATION . . . . . . . . . . . . . . . . . . . . . 13

4.6.1 V isua l Examinat ion . . . . . . . . . . . . . . . . . . 13 4.6.2 Leak Tes ts . . . . . . . . . . . . . . . . . . . . . . 16

5.0 CONCLUSIONS AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 17 5.1 DESIGN STANDARDS . . . . . . . . . . . . . . . . . . . . . . . 17 5.2 WASTE CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . 19 5.3 CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . 19 5.4 AGEANDOTHER . . . . . . . . . . . . . . . . . . . . . . . . 19 5.5 MATERIAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . 20

6 .0 REFERENCES . . . . . . . . . . . . . . . . . 20

ATTACHMENT A - B PLANT LOW LEVEL WASTE ANALYSES

ATTACHMENT B - LEAK TEST DATA SHEETS


B PLANT LOW LEVEL WASTE SYSTEM INTEGRITY ASSESSMENT REPORT

1.0 INTRODUCTION

The Westinghouse Hanford Company (WHC) manages tank systems for the United States Department of Energy-Richland Operations (DOE-RL) that contain dangerous waste constituents as defined by the Dangerous Waste Regulations, in the Washington Administrative Code (WAC) 173-303-040. Chapter 173-303-640(2) of the WAC and 40 CFR 265.191, Subpart J, require the performance of an integrity assessment for each existing tank system that stores or treats dangerous waste. In response to this WAC requirement, the B Plant Low Level Waste System Integrity Assessment Pi an (IAP), WHC-SD-WM-WP-245, was prepared to provide a plan for performing this integrity assessment of the tank system. This integrity assessment report supports compliance with Hanford Facility Agreement and Consent Order interim milestone target action M-32-07-T03.

2.0 OBJECTIVE

The objective is to evaluate the results of the assessment activities and to determine whether the tank system i s adequately designed and has sufficient structural strength and compatibility with the waste to be stored to ensure that it will not collapse, rupture or fail.

The following was considered:

Desiqn standards - Using the original construction codes and standards, identify and evaluate for adequacy the criteria to which the system was constructed and maintained,

Waste' Characteristics - identify the waste and evaluate the adequacy of design to handle the waste,

Corrosion Protection Measures - evaluate the design and the operational

&g - document, estimate, or otherwise determine the approximate age o f

practices for corrosion protection,

the system,

Inteqritv Examination - identify the materials, identify the waste (past and projected), identify the existing condition of the material based upon leak testing, visual examination, and repairs.

1


3.0 SCOPE

The scope, which d i f f e r s from the I A P t o r e f l e c t system changes, inc ludes tanks Tk 24-1, Tk 25-2, and a n c i l l a r y equipment i n c l u d i n g d ischarge p i p i n g t o the f a c i l i t y boundary (west w a l l ) . A lso inc luded are those p o r t i o n s o f t h e f a c i l i t y t h a t serve as secondary containment f o r t he system. See F igure 1, B P lan t Low Level Waste Tank System, f o r a general d e s c r i p t i o n o f t h e system. Tk 25-2 i s in tended f o r use as a one-time storage tank.

NOTE: Tk 25-2 conta ins waste, b u t t he re i s no i n t e n t t o add t o t h e e x i s t i n g i nven to ry o f t h i s tank. Routes t o remove t h e waste f rom t h e tank have no t been i d e n t i f i e d nor has a removal schedule been f i n a l i z e d . Once i d e n t i f i e d , t he a n c i l l a r y equipment used t o remove the waste from Tk 25-2 w i l l be t e s t e d p r i o r t o , and v i s u a l l y monitored dur ing , t he waste t r a n s f e r .

The d e t a i l e d scope o f t h e low l e v e l waste tank system being evaluated and assessed i s as fo l l ows :

Comoonents

Tk 24-1 Low Level Waste C o l l e c t o r -

Tank supports

Tk 25-2 Low Level Waste C o l l e c t o r

Tank supports

P ip ing

P ip ing i n ho t p ipe t rench,

Tk 24-1 ( F ) t o ho t p ipe t rench ( l i n e 206)

P e r t i n e n t Drawinss

H-2-40488, H-2-60924,

H-2-40488, H-2-60336, HW-69880, HW-69881,

H-2-40474, H-2-60925,

H-2-40474, H-2-60336, HW-69880, HW-69881,

H-2-61026 t h r u H-2-61048,

H-2-61026, H-2-60885, H-2-60896,

Jumpers 206 t o 23/24-10, 31/32-8 t o 31/32-10, H-2-34217, and 39/40-8 t o l i n e 244 nozz le i n ho t p ipe t rench H-2-61026,

H-2-61034, H-2-61047,

2

:i

I; z rn m a, I

-$ N

Ir


J

3 0 J

4


Secondary containment

C e l l 24 and C e l l 25

6" d r a i n r i s e r s from c e l l 25 & t h e ho t p ipe t rench t o t h e 24" c e l l d r a i n header, t he c e l l d r a i n header f rom c e l l 25 t o Tk 10-1 i n c e l l 10.

24" C e l l D ra in Header

C e l l 10

Tk 10-1

Hot p i p e t rench

W-69565, W-69566,

W-69565, W-69566,

W-69333, W 69566,

W-69994,

H-2-60910, D e t a i l 61881,

W-69565, W-69566.

Al though tank Tk 25-2 i s no t be ing used as a p a r t o f t h e low l e v e l waste system, i t i s be ing used t o s t o r e aqueous waste generated du r ing organ ic so lvent washes.

4 .0 DESCRIPTION

The f o l l o w i n g sec t ions prov ide t h e system and f u n c t i o n desc r ip t i on , des ign requirements, waste c h a r a c t e r i s t i c s , co r ros ion p r o t e c t i o n measures, age, and o the r f a c t o r s used i n eva lua t i ng t h e design and assessing t h e c o n d i t i o n o f t h e system. Appendix A con ta ins a ' l i s t o f s p e c i f i c a t i o n s and drawings f o r re ference.

4.1 DESCRIPTION AND FUNCTION OF THE LOW LEVEL WASTE SYSTEM

The e x i s t i n g c o n f i g u r a t i o n o f t h e Low Level Waste System was es tab l i shed as a p o r t i o n o f P ro jec ts CAC-144 and CAC-181 i n t h e mid-l960s, which reworked much o f t he f a c i l i t y . have changed. Present ly , most o f t he system i s ' located i n c e l l 24, c e l l 10 and t h e ho t p i p e t rench. Tk 24-1 rece ives e f f l u e n t f rom Tk 10-1, WESF, and o the r condensate d ra ins . The pH o f t h e e f f l u e n t i s ad jus ted i n Tk 24-1 through t h e a d d i t i o n o f sodium hydrox ide s o l u t i o n . Sodium n i t r i t e i s a l s o added t o t h e waste t o meet tank f a r m s p e c i f i c a t i o n s . A f t e r t rea tment i n Tk 24-1, pump P-24-1-2 i s used t o t r a n s f e r t he waste t o the tank farms. f l o w r a t e and pressure are approximately 20 gal /min and 60 lb,/in2 (1.2E-03 m / s and 413 Et03 Pa). Tk 25-2, a f t e r removal o f t h e e x i s t i n g waste i nven to ry , w i l l be removed from serv ice .

ope ra t i ng capac i t y i s l i m i t e d t o 7,500 ga l l ons (28.4 m ) t o ensure t h a t t h e capac i t y o f secondary containment i s n o t exceeded i n t h e case o f a l eak . t ank i s equipped w i t h i n t e r n a l c o o l i n g c o i l s , which are no l onger i n use.

Since then, i t has been rev i sed as t h e f a c i l i t y needs

Trans fer

Tk 24-1 has a capac i t y o f 12,000 ga l l ons (45.4 m'l, however, t h e

The

5

WHC-SO-WM-ER-456 Rev. 0

Administration procedures and a1 arms prevent accumulating inventory beyond the set limits.

The system may handle up to 14,000 gal/month (52.9 m3/m). Waste input to the tank is mostly water received by gravity flow at ambient temperature.

Tk 25-2, which is intended f:r use as a one-time storage tank, has a capacity of 5,000 gallons (18.9 limited to 2,900 gallons (10.9 m ) .

The floor of cell 24, cell 25, and the hot pipe trench are sloped to drains. Cells 24 and 25, as other cells, drain to the B Plant Cell Drain Header. The header in turn drains to Tk 10-1 in cell 10, which serves as a common sump for all of the cells and the hot pipe trench in the 221-8 building. The hot pipe trench has drains at 40 foot (12.9 m) intervals which are routed directly to the cell drain header.

Cell 10, which contains Tk 10-1 (part of the secondary containment system), is located at a lower elevation than the other cells to permit gravity draining. provide a design to prevent the escape of airborne radioactive contamination from the cells to the canyon deck, and provide shielding of the high intensity radiation emanating from the process waste.

Cell 10 is equipped with a sump (tertiary containment) and sump pump that collects and discharges into Tk 10-1 any accumulated leakage or spillage in the cell. monitoring the inventory in tanks Tk 10-1, Tk 24-1, Tk 25-2, and the cell 10 sump. primary or secondary containment in-leakage or out-leakage.

) , however, the operating capacity is

Cover blocks, along with the negative cell pressure,

Leak detection of the system is accomplished by continuously

Any unaccountable change of any of the four inventories indicates

All lines which service cell 24 are embedded in concrete and terminate in a row of "connector nozzles" on the cell walls nine feet (2 .74 m) below canyon deck level. Tk 24-1 and Tk 25-2 are placed on the cell floor and held in position by guides built into the cell, thus establishing a standard relationship between the wall connector nozzles and vessels.

4.2 DESIGN STANDARDS

The following sections contain the design standards found for the low level waste system.

4.2.1 Waste Tank Design Standards

accordance with General Specification for Material Procurement and Shop Fabrication of Class I , 11, ?t 111 Vessels, HW-4311, Rev. 2, dated October 25, 1950.

Tk 24-1 and Tk 25-2 were constructed with stainless steel, Type 347, in

"Class I vessels required all-welded stainless steel construction with carbon steel used only for necessary external attachments. The carbon

6


welds to existing lines and 5% of welds in new lines was required. Hydrostatic testing of this new/existing piping was not required.

The supports for the new hot pipe trenching piping were detailed in drawings H-2-61038, H-2-61039, H-2-61040 and H-2-61044. attached to structural steel supports by U-bolts. The new arrangement for the in-cell piping for cell 24 is shown on drawing H-2-60885.

the tanks, pipe, or other equipment received a .005 inch (.00012 m) coat of Amercoat #33, or equal, followed by a final coat gray. Surface preparation required "white metal blast cleaning" per SSPC-SP5-52T, Steel Structures Painting Council, which is needed for very corrosive atmospheres.

The piping is

All carbon steel used in the hot pipe trench or the cells for support of

4.2.2.2 Other Equipment. Project CAC-144 fitted Tk 24-1 with an agitator to minimize sediment. at 50 gal/min (.003 m / s ) at 90-foot (27.4-m) head for the normal transfer of liquid waste to the tank farms.

Drawing H-9-1069, Pump Vertical Turbine Stainless Steel, provides design and operating criteria for the electrically driven pumps. material, type 304L, is required for the wetted metal parts. found for cast stainless material. 180 "F (82 "C). performance before installation in the tanks.

in accordance with HS-BS-0084, Jumper Fabrication. The jumper material is stainless steel. lb,/inz (689 E+03 Pa) unless otherwise noted on the drawing.

4.2.3 Secondary Containment

The 221-8 building, which houses and supports the low level waste system, was constructed as a reinforced concrete structure, in the early 1940s, as a part o f Project 9536. Many design drawings for the original design are avail ab1 e, but, the design specifications foll owed during the original construction have not been found.

Tt 24-1 is equipped with an electrically driven pump rated

Stainless steel No provision was

The maximum temperature is specified as A run-in test is conducted on all pumps to assure adequate

Jumpers, which are remotely removable sections of piping, are fabricated

The jumpers are hydrostatically pressure tested at 100

The hot pipe trench, cell 24, and cell 25 were also refurbished in the 196Os, mainly by Projects CAC-144 and CAC-181. other portions of the secondary containment were found.

No significant rework of the

The original seismic design requirements or analysis to demonstrate a capability for seismic loading have not been found. preliminary analyses were performed to determine the seismic loading capability of the facility. have been performed. WHC-SD-WM-SA-005, Rev. 0, was issued to demonstrate that the unmodified structure was in compliance with the Hanford Facilities Design Criteria, SDC-4.1, Rev. 11 (1989).

During the 1970s

These were the first seismic analyses known to In 1989, B Plant Canyon Structure Seismic Evaluation,

Compliance with SDC-4.1 seismic requirements assures that the structural capacity of the canyon building will not be exceeded (i. e. no collapse) during a Design Basis Earthquake. However, through-wall cracking in the

9


Attachment A, provide the verification of compliance to the compatibility requirements.

4 . 4 EXISTING CORROSION PROTECTION MEASURES

The external corrosion protection of the low level waste system is provided by the weather enclosure provided by the building and the ventilation system that controls the environment. the system is provided by the selection of the materials, fabrication methods, process fluid chemistry limits, and control of the operating parameters. Routine analysis required by operating procedure, 80-018-035, Transfer Wastes from Tk 25-2 to Underground Storage, limit the percent solids and the concentration of H + or OH radioactivity levels and other waste characteristics as shown in the examples of analysis results in Attachment A. waste is required to be 50 "C or lower. radiation of the waste is normally less than 1 Roentgen/hour. Degradation of the system materials from this rate of radiation should be negligible.

The internal corrosion protection of

ions and measure chloride (since 1990),

The transfer temperature of the tank Analysis records show that the

Material

The original material selected for the tanks, exposed to process fluid, was type 347 stainless steel. Type 304L stainless steel material was used to modify the tanks in the 1960s for their new yission. The gasket material used in the recent past, and currently, is Teflon . Generally, the support material is carbon steel that i s protected from corrosion by a coating material.

Corrosion Allowance

A review of the design documentation found no explicit corrosion allowance for either the original piping system or for changes to the piping or tank systems. However, schedule 40 piping was used where schedule 10 would have been structurally adequate and the minimum tank wall thickness is 1/4 inches (6.35 E-03 in) where 10 gauge (3 .42 E-02 m) would have been adequate for hydraulic containment, therefore, a generous corrosion allowance is implicitly i ncl uded ~

Cathodic Protection

No requirements for cathodic protection were found in the design documentation. There are no metal components in contact with the soil.

4 . 5 AGE OF THE WASTE TANK SYSTEM

The 221-8 building is about 50 years of age, therefore, the secondary containment portion of the low level waste system, other than those noted refurbished areas, are about 50 years of age. The age of the piping in the waste tank system is approximately 30 years or less. Tk 24-1 and Tk 25-2 were originally constructed for use in U Plant in about 1950. In the mid-1960s

'Teflon is a product of the Du Pont de Nemours Company.

12

WHC-SD-WE-ER-456 Rev. 0

Cell 24 and Tk 24-1 - On September 1, 1995, the cover blocks were removed

The objective of the visual examination was to from cell 24 to perform a visual examination of the cell and Tk 24-1 using a remotely controlled CCTV. examine the cell and the tank for evidence of leakage or degradation.

Most of the coating on the floor was gone, no cracks were noticed, but, in some areas there appeared to have been erosion o f the cement between the aggregate to approximately 1" (2.54 E-02 m) depth. Perhaps liquid waste has chemically eroded the binding cement. Several pieces of hardware were scattered about. The trunnions and trunnion guide hardware are mostly carbon steel and have degraded, especially the anchor bolts and plates adjacent to the floor. The significance of the floor erosion does not seriously impede the function of the cell as secondary containment. The concrete floor, which remains sloped to the drain, is 6 feet (1.82 m) thick.

walls received a more rigorous repair than the walls above this level. condition of the walls above and below this level appears very similar at this time. cracks is uncertain. There are a number of -14" (.35 m) diameter holes, several feet above the floor, core drilled through the wall between the cell and the ventilation plenum, which runs parallel to the cells. observed in the cross-section surface, exposed by the core drilling. degradation of the concrete surfaces and the trunnion hardware is evident, but it is not thought to be serious. No cracking of the floor was observed.

During the refurbishment of the 1960s the lower 2 feet ( .60 m) o f the The

Some cracking appears more than superficial, but the extent of these

No cracks were Some

As noted earlier, the degradation of the floor and other areas is a result of past practices and does not represent the effects of the existing system. corrosive to concrete should it be spilled in a cell or elsewhere in the secondary containment.

The liquid waste being collected and transferred is not aggressively

The camera was able to view a portion o f the underside o f the tank. visible portions of the tank, shimmed supports, bottom and side walls appeared in good condition. excess lubricants or process liquid spillage. degradation of the tank was observed.

from cell 25 to perform a visual examination of the cell and tank 25-2 using remotely controlled CCTV. examine the cell and the tank for evidence of leakage or degradation.

when examining cell 24. The floor had an accumulation of precipitate in one area and in a couple other areas there was erosion of the cement between the aggregate. liquid waste spillage during leak testing or jumper and equipment change-out.

The

Stains on the outer shell of the tank were the result of No significant evidence of

Cell 25 and Tk 25-2 - On September 8, 1995, the cover blocks were removed

The objective of the visual examination was to

The findings of this visual examination were very similar to those found

These areas indicate an attack on the cement, most likely by

The walls had cracking, but, the extent of this cracking could not be determined. protective coating and are beginning to show significant corrosion, especially, some of the anchor bolts and plates adjacent to the floor. consequence of the corrosion is insignificant because the trunnion assemblies no longer serve a functional purpose.

The trunnions, and trunnion guides had lost most of the

The

15


The supports and v i s i b l e p o r t i o n s o f t h e tank appeared t o be i n good cond i t i on . beneath t h e tank, but , these are thought the r e s u l t o f excessive l u b r i c a n t .

had degraded t o t h e p o i n t o f no t being adequately f u n c t i o n a l .

o f t he c e l l d r a i n header was performed us ing a c rawler v e h i c l e and CCTV. v ideo tapes were reviewed i n l a t e September 1995 t o examine t h e d r a i n header f o r evidence o f degradat ion o r leakage. found con ta in ing a couple inches ( .05 m) , more o r l ess , o f a m ix tu re o f l i q u i d , sediment, and an occasional depos i t o f sa l tcake appearing substance, which r e t a i n e d a pool o f l i q u i d and sediment upstream. The c rawler broke up these pools, so, on t h e r e t u r n t r i p t h e stream was more uni form. A t several l o c a t i o n s bes ide t h e stream were a d d i t i o n a l depos i ts o f t h e sa l t cake appear ing substance. The sec t ions o f v i t r i f i e d c l a y appeared i n good cond i t i on , t h e r e was no no t i ceab le evidence o f erosion, c rack ing o r d i s c o n t i n u i t y f rom s e c t i o n t o sec t ion . The focus and r e s o l u t i o n o f t h e camera was no t adequate t o determine t h e c o n d i t i o n o f t he cau lk ing a t t he j o i n t s . A t many o f t h e j o i n t s t h e sa l tcake appearing substance extended c i r c u m f e r e n t i a l l y f u r t h e r than between t h e j o i n t s . Presumably, t he cau lk ing ac ts s i m i l a r t o a wick, r a i s i n g t h e l i q u i d mo is tu re which evaporates t o leave a s a l t res idue. evidence o f leakage f r o m the c e l l d r a i n header.

The t r i c k l i n g stream o f water i n t h e c e l l d r a i n header, as observed i n 1989, was no t an i n d i c a t i o n o f leakage from c e l l 24 o r 25 because t h e header a l so c o l l e c t s dra inage from the o the r 30 c e l l s between c e l l 10 and c e l l 40. The source o f t h e water i n t h e header was the r e s u l t o f a c t i v i t i e s i n c e l l s o the r than c e l l 24 o r 25. Operat ing records i n d i c a t e no increase i n Tk 10-1 i nven to ry f r o m t h e c e l l d r a i n header du r ing the past several months.

There were some s t a i n s along the s i d e o f t he tank extending

Genera l ly , no th ing was found t o i n d i c a t e t h a t t h i s p o r t i o n o f t h e system

24" C e l l D ra in Header - I n l a t e 1989 and e a r l y 1990, a v i s u a l examinat ion The

The i n v e r t o f t he d r a i n header was

There was no

The r a d i a t i o n repo r ted du r ing the examinat ion va r ied f rom 100 t o 2700 The temperature i n the d r a i n header, Roentgens/hour (approximate va lues) .

recorded on the crawler , was i n the 60s "F (16 t o 20 " C ) .

4 . 6 . 2 Leak Tests

of t h e low l e v e l waste system. o f these l e a k t e s t s .

Four separate l e a k t e s t s were performed t o check t h e l e a k t i g h t i n t e g r i t y Fo l low ing are b r i e f d e s c r i p t i o n s and r e s u l t s

Trans fer L ine - On March 9, 1995, the t r a n s f e r l i n e , V-244, between d i v e r s i o n box 241-ER-152 and the 23/24-10 nozz le ad jacent t o c e l l 24, i n c l u d i n g jumpers 31/32-8 t o 31/32-10 and 39/40 t o l i n e 244 nozz le, were l e a k t e s t e d i n accordance w i t h Document No. TO-140-170, Rev.E-2, dated 11/7/94, and Document No. 2E-94-00951/0. The l e a k t e s t found the t r a n s f e r l i n e acceptable f o r cont inued use.

descr ibed above was performed t o e s t a b l i s h t h e c o n d i t i o n o f t h e c e l l f l o o r and t h e e x t e r i o r sur face o f t h e ta:k. minimum 7,500 g a l l o n s (28.39 m ) o f waste water. The l i q u i d l e v e l and temperature o f t h e tank was monitored f o r t h e nex t two days and t h i s da ta was recorded on page 10 Procedure No. WP-B-95-035. On September 8, 1995, a f i n a l

16

Tk 24-1 - On September 1, 1995, a base l ine v i sua l examinat ion as

La te r t h a t day, Tk 24-1 was f i l l e d w i t h a


CCTV visual examination of the cell floor and the exterior surface was made to identify any leakage from the tank that may have occurred. No evidence of leakage on the cell floor or the exterior surface of the tank was observed.

Transfer Line - An in-service leak test of the transfer piping from Tk 24-1 to the 23/24 nozzle in the hot pipe trench was conducted on September 8, 1995. the 23/24 nozzle connector appeared to be enlarged, possibly due to mishandling. material, which should continue to function acceptably. good condition. was observed. Observance was via CCTV.

The flexible portion of the jumper immediately upstream of

The jumper is fabricated from corrugated ductile stainless steel The braid appeared in

No evidence of leakage from this piping during the transfer

Tk 25-2 - On September 8, 1995, a baseline visual examination as described above was performed to establish the condition o f the cell floor and the exterior surface of the tank. The tank was filled to approximately 2900 gallons (10.9 m ) of waste water and liquid level and temperature monitoring began on 10/6/95 and continued until 10/10/95. These data were recorded on page 8 of Procedure No. WP-6-95-38. On October 10, 1995, a final CCTV visual examination of the cell floor and the exterior surface was made to identify any leakage from the tank that may have occurred. No evidence of leakage on the cell floor, around the drain, or on the exterior surface of the tank was observed.

5.0 CONCLUSIONS AND RECOMMENDATIONS

This section presents the conclusions drawn from evaluating the system design, waste characteristics, corrosion protection measures, and age. Also included is a study of the results of examinations, tests and past performance of the system to assess the corrosive degradation of the material.

5.1 DESIGN STANDARDS

The design codes and standards listed in section 4.0 for the low level waste system are generally adequate for th? intended function of transferring liquid waste at pressures below 100 lb /in (689 E+03 Pa) and temperatures well below 200 " F (93 "C). Projects CAC-144 and CAC-181, which refurbished a majority of the system, used updated materials, fabrication requirements and installation techniques that maintained the design integrity. acceptable service, the limited operating temperature range, the piping layout, and piping material lead to the conclusion that any thermal analysis of the existing system would not be meaningful. comments are as follows:

The years of

Design observations, and

1. The secondary containment design configuration for waste tanks Tk 24-1 and Tk 25-2 does not fit the description found in section 173-30-640(4)(d) of the WAC. The design configuration fits neither the "liner", "vault", or "double-walled tank" concept, as described in this section. O f the three concepts, this secondary containment is most like the vault configuration. Aspects of the design, other than configuration, appear to meet the WAC functional criteria for these concepts, which is to have the capacity to contain waste

17


5 . 2 WASTE CHARACTERISTICS

Based upon the ignitability, corrosivity, reactivity, and toxicity characteristics of the waste as defined in WAC 173-303-090, the waste was determined not to be ignitable or reactive, but was determined to be corrosive and toxic. is controlled by the use of additives and the toxicity is controlled by features in the design and operating procedures, which prevent the environment from being affected. portions of the secondary containment and support hardware is discussed in paragraph 5.1 and elsewhere herein.

the system design are considered to be adequately compatible.

The corrosiveness of the liquid waste to the primary containment

The corrosiveness of the liquid waste spillage to the

The characteristics of the liquid waste being handled by the system and

5 .3 CORROSION PROTECTION

Corrosion protection measures were included in the original design and have been continued during the system upgrades. The carbon steel material used to construct the trunnion assemblies, which maintain the tanks in proper position, has begun to corrode. The use of ASTM identified materials, or materials within specified chemical limits, qualified welders and welding procedures, and inspection of the welds should have resulted in a level of integrity of the primary liquid waste containment design suitable for the intended service. With some exceptions, the materials selected for fabricating the system are appropriate for the intended service. exceptions are the coating on the carbon steel materials and the coating on the concrete that has degraded. A significant portion of this degradation is thought to have been caused by past practices, which are no longer in effect.

The ventilation system appears to supply a generous flow of air through the cells, thereby, minimizing corrosion by keeping the cells and the system dry. controlling the corrosion rate of the waste tank system.

protection for the system.

The

Cathodic protection is not considered to be an important factor in

The design and operational practices provide the needed corrosion

5 . 4 AGE AND OTHER

Age does not appear to be a significant degradation factor for the tanks and piping. fabricated of similar material, exposed to similar operating conditions in other waste systems at Hanford support this conclusion. herein, there has been some degradation of the secondary containment materials, but, this degradation is not considered to be serious. The drain risers, cell drain header and Tk 10-1, which comprise the remaining portion of the secondary containment, are approximately 50 years of age. The review of the visual examination of cell drain header found no leakage or noticeable evidence of degradation of the vitrified clay pipe.

Wall thickness measurements of piping and tanks of similar age

As noted elsewhere

19


Speci f i c a t i on No.

HW-4311

HS-8s-0084

HS-V-S-0030

820-R-1

Tab le 1. B P l a n t Low Level Waste System S p e c i f i c a t i o n L i s t

T i t l e Remarks

General s p e c i f i c a t i o n f o r m a t e r i a l procurement and shop f a b r i c a t i o n o f Class I , I1 & 111 Vessels

Jumper f a b r i c a t i o n Supersedes

Tes t i ng o f v e r t i c a l t u r b i n e and Supersedes

Heat t rea tment and m a t e r i a l s p e c i f i c a t i o n f o r wrought 1.8-9-S-Cb and 25-12-S-Cb

HWS-5786

submers ib le pumps HWS-10279

A-2


Drawing No.

H-2-60825

H-2-60885

H-2-60896

H-2-60924

H-2-60962

H-2-61026

H-2-61028

Title Remarks

Engineer flow diagram hot pipe trench cell 33, 34, 35 & 36

Cell 24 in-cell piping arrangement

In-Cell piping support details

Cell #24 cell arrangement

Pump arrangements & schedule

Piping plans hot pipe trench cells 23 & 24


H-2-61029 Piping sections hot pipe trench cells 25 & 26

I Pipe support hot pipe trench cells I 17-34

H-2-61030

H-2-61031

H-2-61032

H-2-61033

H-2-61034

H-2-61035

H-2-61036

H-2-61037

H-2-61038


Piping sections hot pipe trench cells 27 & 28







I

H-2-61039

H-2-61040

H-2-61041

A-4

-. - . Supports-steel details hot pipe trench cells 17-40

Hot pipe trench anchors, guides & detai 1 s

Jumper assembly 12-39 hot pipe


Piping plans hot pipe trench cells 37 & 38 Piping sections hot pipe trench cells 37 & 38 Piping plans hot pipe trench cells 39 & 40 Piping sections hot pipe trench cells 39 & 40

Composite assemblies vertical turbine pumps

Standard section (supports & guide arrangement) plans & sections

Standard section (supports & guide arrangement) sections

Piping thru concrete - standard section plans

Piping thru concrete - standard sections

Piping thru concrete - sections 3 & 4

Drawing No.

Cell & piping trench cross-

H-2-61042

Proj. 9536

H-2-61043

Outfall & vent

H-2-61044

Proj. 9536

H-2-61046

H-2-61047

H-2-61048

Tk 10-1

H-2-92573

HW-69880

HW-69881

HW-69882

HW-69883

HW-70101

HW-70103

HW-70426 Detail 61516

Detail 61881

T i t l e Remarks

Piping plans hot pipe trench cells 35 & 36 Piping sections hot pipe trench cells 35 & 36 Pipe supports hot pipe trench cells 34-40

Piping thru concrete - section 15 Cell & piping trench cross-

A-5


ATTACHMENT A

B PLANT LOW LEVEL WASTE ANALYSES

A T T - A I

SAMPLE POINT 25-2 ROUTINE ANALYSIS

;AMPLE POINT 25-2 ROUTINE ANALYSIS

Comments:

p ocLt e, , , , - iaL3

b m cn

t

SlSAlVNV 3NllflOtl 1 5 2 lNlOd 3ldWVS 2 c 4

TK 24-1 LEAK TEST DATA SHEET WHC-SD-WM-ER-456, Rev. 0

I' mporary Work Procedure ~

Proc. No. WP-6-95-035 P1 a n t Rev. A, Mod. 0

ideo Examination O f TK-24-1 And The Hot Pipe Trench Page 10 of 10

Approval To Exceed Step 5 .2 [1 ] )

Operations Manager: - 9/J/!r Data

Process Engineer: 9-/-9s Siprutura Data

ATT-B2


L I N E V-244 LEAK TEST DATA SHEET

5 . 2 PRESSURE TESTING

5.2.1 REqUEST c r a f t personnel START the pressure cyc le AND SLOWLY BUILD UP pressure t i e b b Li ta t , approximately 60 psig/min) L V ; : ~ the pump.

5.2.2 I F leaks a r e observed, perform the following:

5.2.2.1 BLEED OFF the pressure .

5.2.2.2 REQUEST c r a f t personnel t o t i gh ten leaking f i t t i n g s , f l a n g e s , or pressure t e s t assembly connect ions as necessary.

WHEN i d e n t i f i e d l eaks have been co r rec t ed , REPEAT s t eps 5.1.13 t h r u 5.1.15 as necessary t o r e f i l l the t r a n s f e r l i n e .

5.2.2.3

5.2.2.4 PERFORM s t e p 5.2.1 t o bui ld u p p ressure .

5.2.3 WHEN spec i f i ed t e s t .pressure i s reached, CLOSE t h e block valve t o i s o l a t e t h e pump.

5.2.3.1 IF unable t o maintain pressure , OBSERVE the t r a n s f e r l i n e or the encasement and any c leanout boxes (COE) assoc ia ted with the t r a n s f e r 1 ine f o r water leakage .

5.2.3.2 IF a leak i s observed, NOTIFY ? I C .

5.2.4 RECORD t h e s t a r t i n g time and p res sz re , THEN

r e s su re a t 10 minutes, 30 minutes, 4 . ;nc! a t 1 h.i~?r i n the PRESSURE TEST

rmis view/print document cover sheet · 2020-01-16 · collects and discharges into tk 10-1 any...

Documents